SEMESTER INDUSTRIAL TRAINING REPORT ON

FOUNDARY TECHNOLOGY
COMPLETED AT DCM ENGINEERING LTD. ROPAR SUBMITTED BY GURJINDER SINGH
90461126906

DEPARTMENT OF MECHANICAL ENGINEERING

KHALSA COLLEGE OF ENGINEERING & TECHNOLOGY, AMRITSAR(PB), INDIA JUNE, 2013

ACKNOWLEDGEMENT
I am grateful to Dr. Amarpal Singh, Principal, Khalsa College of Engineering & Technology, Amritsar, for providing this opportunity to carry out the Semester Industrial Training at DCM ENGINEERING LTD. ROPAR.

The constant guidance and encouragement received from Prof. Ashok Khanna T&P, KCET Amritsar has been of great help.

The help rendered by Mr. Anil Kaushik & Mr. Vivek Wasson for experimentation is greatly acknowledged.

I also express gratitude to Mr. Naveen Kumar of Mechanical Engineering department of KCET for their intellectual support throughout the course of this work.

GURJINDER SINGH

ABSTRACT

DCM has been an industrial front runner in the Indian sub continent. The history of DCM group goes back to 1889 with the Delhi Cloth Mills, when industry was in its infancy in India. Anticipating the tremendous boom in the automobile sector both nationally and internationally, the DCM Group setup a Grey Iron Foundry in 1977 with the capacity of 17000 MTPA as Division of DCM Limited. This was subsequently hived off as an independent company "DCM Engineering Limited in 2004 (effective April 2001). Capacity of this foundry was increased to 35,000 & 50,000 MTPA in the year 1994-95 & 2005-06 respectively. Recently, this capacity has been increased to 72,000 MTPA. This foundry is one of the leading foundries in India, in the segment of Automotive Castings. The foundry specializes in the manufacture of Cylinder Heads, Cylinder Blocks and Housings. The company has achieved the annual turnover level of INR 4100 million during the year 2010-11 and further, targets growth of more than 20% in ensuing year, 2011-12. DCM is supplying castings across all segments in automotive market: car, multi-utility vehicle, tractor, light commercial vehicle, heavy commercial vehicle and earth moving equipments. DCM is also exporting consistently for last 10 years. Its association with international customers includes General Motors, Perkins Motors UK. In domestic market DCM is associated with top automotive players: Maruti Suzuki India Ltd., Hyundai Motors, Mahindra & Mahindra, International Tractors Ltd., Ashok Leyland, Volvo Eicher Commercial Vechiles Ltd, Tata Cummins Ltd,Kirloskar Oil Engines Ltd.,Suzuki Power Train India Ltd.,Avtec Ltd., Escorts, SML Isuzu Ltd, JCB India, Force Motors, Man Trucks India Ltd., Greaves Cotton Ltd., Simpson & Co and many more. India is emerging as major auto component supplying hub to the global automotive manufacturers resulting in tremendous scope for increased business opportunities in domestic as well as international markets. Set up another plant in south India, project engineering work for which has commenced. "Company employs more than 1700 people at its manufacturing plant at Ropar, Punjab. At its Ropar plant company houses two high pressure moulding lines with press pour state of the art tooling & designing facility in addition to other supporting processes and equipments." Companys registered office is at New Delhi. It is a subsidiary of DCM Limited. DCM Engineering Limited is not a listed entity. Its holding company is however listed at BSE and NSE.

HISTORY

DCM Engineering Limited is part of the DCM group. DCM started its journey with formation of public limited Company incorporated on March 26, 1889 in the name and style of Delhi Cloth & General Mills Co. Ltd. under the provisions of Act VI of 1882. The name of the Company was changed on October 6, 1983 to DCM Limited. DCM started its operations in 1889 by establishing a spinning mill at Delhi. Over the years, it expanded and diversified its activities into a number of manufacturing activities such as Textiles, Sugar, Chemicals, Rayon, Tyre Cord, Fertilizers, Electronic Data Processing Machines and Engineering Products etc. The business of the Company was reorganized with effect from 1.4.1990 under a Scheme of Arrangement under section 391 / 394 of the Companies Act, 1956 approved by the shareholders, creditors and the financial institutions and sanctioned by the Honourable High Court of Delhi at New Delhi in CP No. 4 of 1990 vide an order dated 16.4.1990. Under the said reorganization, all units of the Company existing at that time stood vested and / or continued to vest in terms of the said Scheme into four separate companies namely,

Engineering)

The Company along with its subsidiaries has been engaged, inter alia in the following business activities:

Scheme of Restructuring and Arrangement In order to restructure its debt in just and equitable manner and to ensure the growth avenues for the operating businesses, DCM formulated a comprehensive Scheme of Restructuring and Arrangement which was approved by the court and notified on 2.1.2004 under section 391394 of the Companies Act.

GROUPS DCM Engineering Limited is part of the DCM group, one of Indias leading business conglomerates. Over this long period of history DCM has build its corporate philosophy synonymous with corporate dynamism and business integrity. The groups diverse business interests today include: 1. Textile Business: www.dcmtextiles.com DCM Textiles, division of DCM Limited and headed by Dr. Vinay Bharat-Ram (Chairman & Managing Director); is engaged in the business of yarn spinning with capacity of 56,628 spindles and having annual turnover of INR 873.80 millions during the year 2005-06. DCM Textiles is mainly engaged in making cotton yarn in single and two-ply forms. The company has strong marketing network for its products. 2. Purearth Infrastructure Limited(Real Estate Business): www.centralsquare.in DCM is the owner of plot of land measuring about 66.53 acres situated at Bara Hindu Rao/ Kishan Ganj, Delhi, comprising of both freehold and leasehold land. All development rights for the said Real Estate Project have been conveyed to Purearth Infrastructure Limited (earlier called DCM Estate and Infrastructure Ltd. (DEIL) under the Scheme. Purearth Infrastructure Limited would undertake the development of entire project and would be responsible for the construction and sale of Project. Construction work at the site is presently in progress. 3. IT Division: www.dcmtech.com DCM established its IT Division in the year 1972 with establishing of DCM Data Systems. It is one of the oldest Indian IT companies that have continuously adapted itself to changing business and technical scenario. The IT division of DCM Ltd has been formed by merging the Infrastructure Services CompanyDCM Data Systems with the Technology & Design company-DCM Technologies in 2004. Today it offers larger array of services:

Enterprise System Management Services Customer Support Services Embedded Systems Software for Automobiles Embedded Systems Software for Wireless

VISION & VALUES

VISION : Vision to become preffered supplier of castings to world's leading Companies. VALUES : Tenacity

Team Work

-operation

Customer Focus

Learning Organisation

Fair and Just to Employees

ways hear/listen what other has to say

Integrity and Transparency

upright in character

OUR PRODUCTS AND CUSTOMERS

1: CARS

Maruti Suzuki Maruti suzuki Hyundai Motors Avtec

COMMERCIAL VEHICLE

Volvo Eicher Ashok Leyland MAN Force Volvo Eicher Ashok Leyland MAN Force

Tata Cummins Simpson & Co. Tata Cummins Simpson & Co. Kirloskar Oil Perkins UK

Kirloskar Oil Perkins UK Tata Cummins Simpson & Co. Kirloskar Oil Perkins UK

ENGINE ASSEMBLERS & MANUFACTURERS

TRACTORS AND CONSTRUCTION EQUIPMENT

Mahindra (FES) Escorts Tractors Sonalika Tractors Mahindra (FES) Escorts Tractors Sonalika Tractors Swaraj

YGYHGJU

Hyundai Motors India Ltd

Maruti Suzuki India Ltd

Farmtrac Ltd.

Mahindra & Mahin

International Tractors Limited (Sonalika)

Tata Cummins Ltd.

JCB India Ltd.

Simpson & Com

General Motors

SML Isuzu Ltd.

Ashok Leyland Ltd.

Force Motors Ind

V.E. Commercial Vehicles Ltd.

Mahindra & Mahindra

Perkins UK

International Cars & Mo (ICML)

Greaves Cotton Ltd.

AVTEC Ltd.

Suzuki Powertrain India Ltd.

Kirloskar Oil Engi